Mercury 115 -1,3,5 no spark with good power packs

[WANTONSOUPGUY]

I was doing some recent work on my 115 and noticed an ignition switch box or power pack was kind of loose. It was running when I touched it, pushing it against the frame to see how loose it was. Since that moment it wont start and I have no spark on cylinders 1,3, and 5. I swapped the power packs with each other to determine if it was a cooked pack, and I still have the Same issue...1,3,and 5 give no spark. That tells me it's not the packs. Does anyone know what to diagnose from here? (and how!)

 

[Laddies]

Re: Mercury 115 -1,3,5 no spark with good power packs

If you swap the stator leads, red to red/white and blue to blue/white the spark will probably goto 2,4 and 6 cyls, that will mean 1/2 of the stator is burned out.

 

[CharlieB]

Re: Mercury 115 -1,3,5 no spark with good power packs

And be very careful with those ignitions in the future, a poor ground will take out a box in about a second.

Ditto the stator advise, repost with your findings.

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Ok. I swapped the blu/red wires with blu/red with white stripe...and...now I have 2,4,6 with no spark...you think it's a stator? Previous to the recent shortout, could a bad stator have been a cause for a high speed popping, lack of top end?

thanks for your replies.

 

[CharlieB]

Re: Mercury 115 -1,3,5 no spark with good power packs

Congrats, you just proved that both boxes and all the coils are GOOD, triggers too.

The stator is actually TWO seperate stators combined into one housing, feeding two seperate ignition systems that share the triggers.

Yes, your stator was going bad, causing your previous problems, now one side is gone. Time to replace it. One of the best on the market is from CDI, they may be handled thru the iBoats store or you may contact them directly.

You will need the correct flywheel puller.

 

[mmccurry]

Re: Mercury 115 -1,3,5 no spark with good power packs

CharlieB is right....You've got a stator that needs to be replaced. Mine did the same thing. If you don't have a Mercury flywheel puller you can go to AutoZone and get a "harmonic balancer puller" on the free loan-a-tool program. It will work just fine in pulling the flywheel on these Merc inline engines.

Just be careful when you install the stator and make sure the wires are pulled down and secured out of the way of the spinning flywheel. I didn't and caused the wires to get cut when I started the engine....I was able to splice the wires and save myself from buying a 2nd stator but it was somewhat frustrating.

Good Luck

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Great. I will order a stator today. I know this is a stupid question, but to pull the flywheel, will this alter the timing, as I notice some timing marks on the side. Also, will it come loose by just loosening the large center bolt?

Thanks again all.

 

[j_martin]

Re: Mercury 115 -1,3,5 no spark with good power packs

CharlieB is right....You've got a stator that needs to be replaced. Mine did the same thing. If you don't have a Mercury flywheel puller you can go to AutoZone and get a "harmonic balancer puller" on the free loan-a-tool program. It will work just fine in pulling the flywheel on these Merc inline engines.

Just be careful when you install the stator and make sure the wires are pulled down and secured out of the way of the spinning flywheel. I didn't and caused the wires to get cut when I started the engine....I was able to splice the wires and save myself from buying a 2nd stator but it was somewhat frustrating.

Good Luck

A caveat is needed here. When you strap down the wires, be sure the trigger wires are on top of the bundle, and free to move with the trigger through the full range of timing while staying free of the flywheel. I usually strap everything down well except the trigger harness, which is only under the ty-wrap on the switchbox mounting plate.

hope it helps
John

 

[CharlieB]

Re: Mercury 115 -1,3,5 no spark with good power packs

The flywheel is keyed to a taper on the shaft, held by the one large nut and washer.

Because of this 'key' timing will not be affected.

You need the correct puller to pull directly up on the inner hub of the flywheel after you loosen the nut.

DO NOT, repeat, DO NOT use any pry bars, outer 'jaw' pullers, or any other puller other than the 'hub' or bolted flange type pullers.

The flywheel can be warped, damaged, or cracked, virtually becoming a BOMB at RPM, if the wrong type pulley is used.

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Thanks to your posts, I found that this flywheel is indeed a 2 part flywheel. I pulled the 8 bolts on the outskirts and the 10? near the large center bolt. The flywheel came off without any effort. I was then able to pull the stator easily with a hex head. I ordered one today. I will let you know how it goes.

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Ok. I installed the stator....but theres a catch. Initially, I put it in exactly like the old one was, until I read a paper that was in the box to install it one position different. So I readjusted to match the paper, but it huffs and pops like its about to backfire and only runs for a second or 2. I'm putting it back to the way it was...hoping this will fix it. Sigh.

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

oK. I put the stator the way the instructions tell me. I set the mark on the flywheel to the pointer when cylinder #1 is at TDC. I have spark on all cylinder, but it acts as if the timing is off and i'm afraid of a serious backfire. Any ideas?

 

[Laddies]

Re: Mercury 115 -1,3,5 no spark with good power packs

The stator has nothing at all to do with timing, check the trigger for movment and the trigger wires on the boxes.

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Should the trigger move?

 

[Laddies]

Re: Mercury 115 -1,3,5 no spark with good power packs

As the throttle lever moves it moves the trigger to advance or retard the timing

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Last I saw, yes, the movement was fine. It ran ok with a high end sputter, then suddenly I lost 3 cylinders of spark. Now that the new stator is in I have spark, but it seems like the timing is off. Now let me ask a stupid question...theres 2 yellow wires coming from the stator to the rectifier. If these were misplaced(swapped), would this cause my problem? One of the yellow wires attaches where there is another wire, and one does not.

 

[j_martin]

Re: Mercury 115 -1,3,5 no spark with good power packs

The 2 yellow wires are exactly the same color BECAUSE they are interchangable. They supply the power for charging the battery. The grey wire coming off one of them goes to the tachometer (if you have one)

That flywheel is not supposed to be take apart at the flex plate. Are you sure you reassembled it properly? Could it be out of clock or off center?

The proper tool is always the best one. In this case, the mercury flywheel removal tool which pulls it by the threaded center hole.

hope it helps
John

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Thanks for the wire clarification, John. I removed the flywheel by 8 small bolts near the large center flywheel bolt. It came off without the use of a puller and I simply replaced the stator. The flywheel Does have some timing marks, of which I tried to align the mark ".464" with TDC. (the marks are as follows, from left to right ".464, 21, 9,6,3,0,5,10,15.") I picked .464 for TDC because it has a mark above and below it. I'm not sure what to do.,..

 

[Laddies]

Re: Mercury 115 -1,3,5 no spark with good power packs

STOP, go back and reread the answers you have received and you should be able to figure it out, you have received good answers. If not buy a OEM manual. You are apparently lost in them or simply don't understand them and need a manual to clarify it.

 

[WANTONSOUPGUY]

Re: Mercury 115 -1,3,5 no spark with good power packs

Sure, Laddies, the answers are helpful...but i'm on the verge of figuring this out...as with other posts it's one thing at a time. Do enlighten me with your timing wisdom. As posted above, the flywheel is "keyed" but this doesnt matter because I removed it NOT by the center bolt, but by the 8 bolts on the flywheel (see above posts). So, then, how would you reset the timing Lad? Do share.